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Daewoo Doosan wheel LOADER DL300-5 / DL350-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD
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Daewoo Doosan wheel LOADER DL300-5 / DL350-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD
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Description
Daewoo Doosan wheel LOADER DL300-5 / DL350-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan wheel LOADER DL300-5 / DL350-5 Serial Number 10001 and Up – PDF DOWNLOAD
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service. Untrained operators and failure to follow instructions can cause death or serious injury.
SAFETY MESSAGES
Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance.
Signal Words
The signal words “DANGER”, “WARNING”, “CAUTION” are used throughout safety messages and safety decals in this manual or on the machine. They indicate an existence of, and the relative seriousness of, a hazard. All three indicate that a safety risk is involved. Observe the precautions indicated whenever a Safety Alert Symbol is present, no matter which signal word appears next to it.
GENERAL
Safe Operation is Operator’s Responsibility Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate the machine.
• When working with other personnel on a work site, be sure that all personnel know the nature of work and understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
• Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt. Use them always. • Never remove, modify or disable any safety features. Always keep them in good operating condition.
• Always check for and know the location of underground and overhead utility lines before working.
• Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury
Know Your Machine
Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances. Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes, etc., can change operating capabilities of your machine
Proper Work Tools and Attachments
- Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual. Because DOOSAN cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact DOOSAN for written authorization and approval of attachments, and their compatibility with optional kits
- Attachments and attachment control systems that are compatible with the machine are required for safe and reliable machine operation. Do not exceed maximum operating weight (machine weight plus attachment) that is listed on ROPS certification plate. Make sure that all guards and shields are in place on machine and on work tool.
- Depending on type or combination of work equipment, there is a potential that work equipment could interfere with the cabin or other parts of machine.
- Before using unfamiliar work equipment, check if there is any potential for interference, and operate with caution. While you are performing any maintenance, testing, or adjustments to attachments, stay clear of the following areas: cutting edges, pinch points, and crushing surfaces.
- Never use attachment as a work platform or manlift. Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation. If you are in doubt about the compatibility of a particular attachment with the machine, consult your DOOSAN distributor
Pressurized Fluids
- Pressurized air or fluids can cause debris and/or fluids to be blown out. This could result in death or serious injury. Immediately after operation is stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures and the radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down.
- Follow specified procedures when attempting to remove caps, drain oil or coolant, or replacing filters. Always wait for temperature to cool down, and follow specified procedures when performing these operations. Failure to do so can result in death or serious injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection.
- Eye protection includes goggles or a protective face shield. Pressure can be trapped in a hydraulic system and must be relieved before maintenance is started. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip or oil to spray. Fluid penetration can result in death or serious injury.
- If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Obey all local laws and regulations for disposal of liquids. To prevent hot coolant from spraying out, stop engine and wait for coolant to cool. Using gloves, slowly loosen cap to relieve pressure.
TABLE OF CONTENTS:
Daewoo Doosan wheel LOADER DL300-5 / DL350-5 Shop Manual Serial Number 10001 and Up – PDF DOWNLOAD
DL300-5/DL350-5.......................................................................................................................................... 0 Table of Contents.................................................................................................................................... 7 Safety............................................................................................................................................... 9 Wheel Loader Safety.............................................................................................................................. 11 Safety Instructions.......................................................................................................................... 15 Safety Messages.............................................................................................................................. 15 General...................................................................................................................................... 17 Safe Operation is Operator's Responsibility.............................................................................................. 17 Know Your Machine........................................................................................................................ 17 Proper Work Tools and Attachments........................................................................................................ 17 Pressurized Fluids....................................................................................................................... 18 Flying or Falling Objects................................................................................................................ 19 Personal Protective Equipment (PPE)...................................................................................................... 19 Correction of Machine Problems........................................................................................................... 20 Crushing and Cutting..................................................................................................................... 20 Hot Coolant and Oils - Burn Prevention................................................................................................... 21 Fire and Explosion Prevention............................................................................................................ 21 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit).............................................................................. 25 Electrical System and Electrical Shock................................................................................................... 25 Operation.................................................................................................................................... 28 Before Engine Starting................................................................................................................... 28 Work Site................................................................................................................................ 28 Check Tire Pressure and Condition........................................................................................................ 29 Mounting/Dismounting..................................................................................................................... 29 Cleaning................................................................................................................................. 30 Operator Station......................................................................................................................... 30 Seat Belt................................................................................................................................ 31 Visibility Information................................................................................................................... 32 Boost Starting or Charging Engine Batteries.............................................................................................. 33 Starting Engine.......................................................................................................................... 34 Traveling................................................................................................................................ 34 Lifting and Digging...................................................................................................................... 36 Digging Beneath Overhangs................................................................................................................ 36 Digging Beneath Wheel Loader............................................................................................................. 36 Operation on Slopes...................................................................................................................... 37 Attachment............................................................................................................................... 38 Equipment Lowering with Engine Stopped................................................................................................... 38 Preventing Risk of Injuries or Death From Boom and Bucket................................................................................ 38 Engine Stop.............................................................................................................................. 40 Parking Machine.......................................................................................................................... 40 Maintenance.................................................................................................................................. 41 Cleaning................................................................................................................................. 44 Proper Tools and Clothing................................................................................................................ 44 Disassembling Precautions................................................................................................................ 44 Use of Lighting.......................................................................................................................... 45 Fire and Explosion Prevention............................................................................................................ 45 Burn Prevention.......................................................................................................................... 46 Rubber That Contains Fluorides........................................................................................................... 47 Rubber and Plastics...................................................................................................................... 48 Welding Repairs.......................................................................................................................... 49 Working on Machine....................................................................................................................... 50 Lock Inspection Covers................................................................................................................... 51 Accumulator.............................................................................................................................. 51 Compressed Air........................................................................................................................... 51 Supports and Blocking for Work Equipment................................................................................................. 52 High-pressure Lines, Tubes and Hoses..................................................................................................... 52 Battery.................................................................................................................................. 53 Preservation/Storing Machine............................................................................................................. 54 Transportation............................................................................................................................... 56 Obey State and Local Over-the-Road Laws and Regulations.................................................................................. 56 Loading and Unloading.................................................................................................................... 56 Transporting Machine..................................................................................................................... 57 Environment and Circumstances................................................................................................................ 58 Work Site Areas Requiring Extra Caution.................................................................................................. 58 High-voltage Cables...................................................................................................................... 60 Underground Operation.................................................................................................................... 60 Working in Water......................................................................................................................... 61 Working in Contaminated Environment...................................................................................................... 61 Operation in Extreme Conditions.......................................................................................................... 62 Exhaust Ventilation...................................................................................................................... 66 Asbestos Information..................................................................................................................... 66 Silica Dust Information.................................................................................................................. 67 Disposal of Hazardous Materials.......................................................................................................... 67 Sound.................................................................................................................................... 67 Vibration Information.................................................................................................................... 68 Specifications....................................................................................................................................... 71 Specification.................................................................................................................................... 73 Safety Instructions.......................................................................................................................... 77 General...................................................................................................................................... 77 Component Locations.......................................................................................................................... 78 Working Range and Dimensions................................................................................................................. 82 Working Capacities........................................................................................................................... 85 Bucket Capacity.......................................................................................................................... 85 Stability Data (EN - and ISO - Norms).................................................................................................... 85 General Specifications....................................................................................................................... 86 Performance Tests............................................................................................................................ 88 Purpose of Performance Tests............................................................................................................. 88 Kinds of Tests........................................................................................................................... 88 Performance Standards.................................................................................................................... 88 Precautions for Evaluation of Test Data.................................................................................................. 88 Definition of "Performance Standard"..................................................................................................... 88 Preparation for Performance Tests............................................................................................................ 89 The Machine.............................................................................................................................. 89 Test Area................................................................................................................................ 89 Precautions.............................................................................................................................. 89 Make Precise Measurement................................................................................................................. 89 Operational Performance Standard Table....................................................................................................... 90 Operational Performance Test................................................................................................................. 94 Engine Speed............................................................................................................................. 94 Front Speed.............................................................................................................................. 96 Natural Subsidence of Cylinder........................................................................................................... 97 Travel Speed - Acceleration and Deceleration............................................................................................. 98 Steering Time............................................................................................................................ 99 Pressure Set............................................................................................................................. 100 Approximate Weight of Workload Materials..................................................................................................... 102 Material Weight.......................................................................................................................... 102 General Maintenance.................................................................................................................................. 105 General Maintenance Instructions................................................................................................................. 107 Safety Instructions.......................................................................................................................... 111 Welding Precautions and Instructions......................................................................................................... 112 Hydraulic System - General Precautions....................................................................................................... 113 Maintenance Service and Repair Procedure..................................................................................................... 115 General Precautions...................................................................................................................... 115 Hydraulic System Cleanliness and Oil Leaks................................................................................................... 116 Maintenance Precautions for Hydraulic System Service..................................................................................... 116 Oil Leakage Precautions.................................................................................................................. 117 Cleaning and Inspection...................................................................................................................... 118 General Instructions..................................................................................................................... 118 Bearing Inspection....................................................................................................................... 119 Standard Torques................................................................................................................................. 127 Safety Instructions.......................................................................................................................... 131 Torque Values for Standard Metric Fasteners.................................................................................................. 132 Torque Values for Standard U.S. Fasteners.................................................................................................... 133 Type 8 Phosphate Coated Hardware............................................................................................................. 135 Torque Values for Hose Clamps................................................................................................................ 136 ORFS Swivel Nut Recommended Torque........................................................................................................... 136 Torque Values for Split Flanges.............................................................................................................. 137 Torque Wrench Extension Tools................................................................................................................ 138 Torque Multiplication.................................................................................................................... 138 Other Uses for Torque Wrench Extension Tools............................................................................................. 139 Tightening Torque Specifications (Metric)................................................................................................ 140 Engine............................................................................................................................................... 143 Engine........................................................................................................................................... 145 Safety Instructions.......................................................................................................................... 151 Overview..................................................................................................................................... 152 Inspection................................................................................................................................... 153 Cleaning the Engine...................................................................................................................... 153 Special Tools................................................................................................................................ 153 Mounting the Engine in a Universal Stand................................................................................................. 163 Engine Identification........................................................................................................................ 164 Engine Data Plate........................................................................................................................ 164 Engine Specification......................................................................................................................... 165 Engine Performance Curves.................................................................................................................... 166 Tightening Torques........................................................................................................................... 168 Normal Tightening Torque................................................................................................................. 168 Special Tightening Torque................................................................................................................ 172 Cylinder..................................................................................................................................... 198 Cylinder Head............................................................................................................................ 198 Valve Mechanism.......................................................................................................................... 216 Cylinder Block........................................................................................................................... 219 Cylinder Liner........................................................................................................................... 234 Flywheel Housing......................................................................................................................... 241 Front Cover.............................................................................................................................. 244 Oil Mist Separator....................................................................................................................... 246 Actuating System............................................................................................................................. 252 Camshaft................................................................................................................................. 252 Connecting Rod........................................................................................................................... 259 Crankshaft............................................................................................................................... 262 Flywheel................................................................................................................................. 271 Piston................................................................................................................................... 276 Roller Tappet............................................................................................................................ 282 Intake Manifold.......................................................................................................................... 283 Power Take Off........................................................................................................................... 283 Torsion Damper........................................................................................................................... 284 Belt Circuit............................................................................................................................. 285 Balance Shaft Unit....................................................................................................................... 291 Timing Gear.............................................................................................................................. 296 Lubrication System........................................................................................................................... 302 General Information...................................................................................................................... 302 Centrifugal Oil Cleaner.................................................................................................................. 304 Oil Cooler............................................................................................................................... 309 Oil Filter............................................................................................................................... 312 Oil Pump................................................................................................................................. 313 Oil Sump................................................................................................................................. 315 Oil Pressure Sensor...................................................................................................................... 316 Troubleshooting Chips Found in the Engine................................................................................................ 317 Troubleshooting the Lubrication System................................................................................................... 321 Lubrication Oil Consumption.............................................................................................................. 322 Exhaust System............................................................................................................................... 325 General Information...................................................................................................................... 325 T113, Exhaust Temperature Sensor Before Catalytic Converter.............................................................................. 340 T131 NOx Sensor.......................................................................................................................... 342 T116, Reductant Pick-up Unit............................................................................................................. 344 Evaporator............................................................................................................................... 349 V117 Reductant Doser..................................................................................................................... 350 V118, Coolant Valve for Heating the Reductant System..................................................................................... 356 V183 Reductant Pump...................................................................................................................... 358 H25, H26 Electrically Heated Reductant Hose.............................................................................................. 369 M4000 Electric Exhaust Brake............................................................................................................. 370 Reductant Tank........................................................................................................................... 376 Oxidation Catalytic Converter............................................................................................................ 383 Exhaust Manifold......................................................................................................................... 385 Variable Geometry Turbocharger........................................................................................................... 393 EGR System............................................................................................................................... 401 EGR Valve................................................................................................................................ 407 EGR Cooler............................................................................................................................... 412 Cooling System............................................................................................................................... 414 Internal Cleaning of Cooling System...................................................................................................... 417 Charge Air Cooler........................................................................................................................ 418 Charge Air Temperature Sensor............................................................................................................ 420 Charge Air Pressure Sensor............................................................................................................... 422 Thermostat............................................................................................................................... 423 Coolant Pump............................................................................................................................. 426 Coolant Temperature Sensor............................................................................................................... 427 Fuel System.................................................................................................................................. 429 General Information...................................................................................................................... 429 Accumulator.............................................................................................................................. 434 Fuel Manifold............................................................................................................................ 435 Overflow Valve........................................................................................................................... 443 Feed Pump................................................................................................................................ 447 Injector................................................................................................................................. 453 Fuel Filter.............................................................................................................................. 459 Fuel Heater.............................................................................................................................. 464 Fuel System Troubleshooting.............................................................................................................. 465 Electrical System............................................................................................................................ 478 E44, Control Unit EMS.................................................................................................................... 478 Control Unit EEC......................................................................................................................... 494 Clamping and Routing the Electrical Cables............................................................................................... 499 Engine Speed Sensor...................................................................................................................... 500 T110 Oil Level Sensor.................................................................................................................... 502 T111, Fuel Pressure Sensor............................................................................................................... 503 T125, Exhaust Back Pressure Sensor....................................................................................................... 505 T135, Camshaft Position Sensor........................................................................................................... 506 V109, Solenoid Valve for Charge Pressure................................................................................................. 508 V120, Fuel Inlet Metering Valve.......................................................................................................... 509 V142, V143, V144, V145, V146 Solenoid Valve for Injector................................................................................. 511 T8, Coolant Level Monitor................................................................................................................ 512 P3, Alternator........................................................................................................................... 513 M1, Starter Motor........................................................................................................................ 523 Electrical Parts......................................................................................................................... 526 EMS S8 (1/2)................................................................................................................................. 537 EMS S8 (2/2)................................................................................................................................. 539 EEC, EEC3 Exhaust Emission Control........................................................................................................... 541 Drivetrain........................................................................................................................................... 543 Transmission and Torque Converter (4WG).......................................................................................................... 545 Safety Instructions.......................................................................................................................... 549 General...................................................................................................................................... 550 Specification............................................................................................................................ 551 Overview................................................................................................................................. 552 Section View............................................................................................................................. 554 Hydraulic Circuit (4-speed Transmission)................................................................................................. 556 Electrohydraulic Control with Proportional Valves........................................................................................ 560 Controller............................................................................................................................... 561 Electric Control System.................................................................................................................. 562 Speed Sensor............................................................................................................................. 565 Measuring Points and Connections............................................................................................................. 568 Transmission Electric Components............................................................................................................. 570 Engine Pickup Sensor..................................................................................................................... 573 Central Gear Pickup Sensor............................................................................................................... 573 Turbine Pickup Sensor.................................................................................................................... 573 Output Speed Sensor...................................................................................................................... 573 Shift Lever Switch (DW-3)................................................................................................................ 574 Transmission Shift Switch................................................................................................................ 577 T/M Cutoff Sensor........................................................................................................................ 577 LIS Solenoid Valve....................................................................................................................... 577 Transmission Electrical Circuits............................................................................................................. 578 Transmission Controller Circuit.......................................................................................................... 578 Traveling Circuits....................................................................................................................... 579 Downshift................................................................................................................................ 587 Transmission Cutoff Switch............................................................................................................... 594 Torque Limits for Screws..................................................................................................................... 595 Special Tools................................................................................................................................ 596 List of Special Tools for Disassembly and Reassembly..................................................................................... 596 Transmission Oil............................................................................................................................. 599 Oil Grade of Transmission................................................................................................................ 599 Disassembly.................................................................................................................................. 600 Electrohydraulic Control and Transmission Filter (Replaceable Filter).................................................................... 600 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug................................................................... 605 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor............................................... 606 Outputs and Closure Parts Pump Shaft (PTO-Shaft)......................................................................................... 610 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches................................................................ 612 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft........................................................................................ 617 Reassembly................................................................................................................................... 641 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft........................................................................................ 641 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches................................................. 681 Outputs and Closure Parts Pump Shaft (PTO-shaft)......................................................................................... 688 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor (Measuring Point "63" After the Converter).... 693 Emergency Steering Pump.................................................................................................................. 698 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug................................................................... 699 Electrohydraulic Control with Proportional Valves:....................................................................................... 700 Failure Code................................................................................................................................. 708 Transmission and Torque Converter (5WG) (Option)................................................................................................. 735 Safety Instructions.......................................................................................................................... 739 General...................................................................................................................................... 740 Specification............................................................................................................................ 741 Overview................................................................................................................................. 742 Hydraulic Circuit (5-speed Transmission)................................................................................................. 744 Torque Convertor......................................................................................................................... 745 Transmission Electric Components............................................................................................................. 746 Transmission Oil Temperature Sensor...................................................................................................... 748 Engine Pickup Sensor..................................................................................................................... 748 Central Gear Pickup Sensor............................................................................................................... 748 Turbine Pickup Sensor.................................................................................................................... 749 Output Speed Sensor...................................................................................................................... 749 Shift Lever Switch (DW-3)................................................................................................................ 749 T/M Cutoff Sensor........................................................................................................................ 753 LIS Solenoid Valve....................................................................................................................... 753 T/M Converter Lockup P/V................................................................................................................. 753 Transmission Electrical Circuits............................................................................................................. 754 Transmission Controller Circuit.......................................................................................................... 754 Traveling Circuits....................................................................................................................... 755 Torque Converter Lockup (Option)......................................................................................................... 756 Torque Limits for Screws..................................................................................................................... 757 Special Tools................................................................................................................................ 758 List of Special Tools for Disassembly and Reassembly..................................................................................... 758 Transmission Oil............................................................................................................................. 761 Oil Grade of Transmission................................................................................................................ 761 Disassembly.................................................................................................................................. 762 Electrohydraulic Control and Transmission Filter (Replaceable Filter).................................................................... 762 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug................................................................... 767 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor............................................... 768 Outputs and Closure Parts Pump Shaft (PTO-Shaft)......................................................................................... 772 Removal of Input Shaft, Output Shaft, Pump Shaft (PTO-shaft) and Clutches................................................................ 774 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft........................................................................................ 779 Reassembly................................................................................................................................... 803 Clutches KV/KR/K1/K2/K3/K4 Input and Output Shaft........................................................................................ 803 Installation of Input Shaft, Output Shaft, Pump Shaft (Power-takeoff Shaft) and Clutches................................................. 843 Outputs and Closure Parts Pump Shaft (PTO-shaft)......................................................................................... 850 Engine Connection, Oil Pressure Pump, Converter Back-pressure Valve and Temperature Sensor (Measuring Point "63" After the Converter).... 855 Emergency Steering Pump.................................................................................................................. 860 Inductive Sensor, Hall Sensor, Breather, Oil Filler and Oil Drain Plug................................................................... 861 Electrohydraulic Control with Proportional Valves:....................................................................................... 862 Front Axle....................................................................................................................................... 871 Safety Instructions.......................................................................................................................... 875 General...................................................................................................................................... 875 Specification............................................................................................................................ 875 Overview................................................................................................................................. 876 Parts List............................................................................................................................... 877 Lubrication and Maintenance Instructions..................................................................................................... 879 Oil Grade................................................................................................................................ 879 Oil Change............................................................................................................................... 879 Carry Out Wear Measurement on the Multidisk Brake........................................................................................ 881 Tightening Torques for Screws............................................................................................................ 882 Differential System.......................................................................................................................... 883 Theory of Differential Device............................................................................................................ 883 Structure of Differential Device......................................................................................................... 884 LSD.......................................................................................................................................... 885 Overview LSD (Limited Slip Differential)................................................................................................. 885 LSD (Limited Slip Differential).......................................................................................................... 886 Axle Air Breathing........................................................................................................................... 887 Special Tools................................................................................................................................ 888 List of Special Tools for Disassembly and Reassembly..................................................................................... 888 Axle Oils.................................................................................................................................... 895 Oil Grade ZF-Powerfluid.................................................................................................................. 895 Removal...................................................................................................................................... 896 Disassembly And Reassembly................................................................................................................... 900 Disassembly Output and Brake............................................................................................................. 900 Disassembly Axle Housing................................................................................................................. 906 Disassembly Input........................................................................................................................ 907 Disassembly Differentials................................................................................................................ 910 Reassembly Differentials................................................................................................................. 917 Reassembly Input......................................................................................................................... 929 Reassembly Axle Housing.................................................................................................................. 937 Reassembly Output and Brake.............................................................................................................. 939 Rear Axle........................................................................................................................................ 953 Safety Instructions.......................................................................................................................... 957 General...................................................................................................................................... 957 Specification............................................................................................................................ 957 Overview................................................................................................................................. 958 Parts List............................................................................................................................... 959 Lubrication and Maintenance Instructions..................................................................................................... 962 Oil Grade................................................................................................................................ 962 Oil Change............................................................................................................................... 962 Carry Out Wear Measurement on the Multidisk Brake........................................................................................ 964 Tightening Torques for Screws............................................................................................................ 965 Differential System.......................................................................................................................... 966 Theory of Differential Device............................................................................................................ 966 Structure of Differential Device......................................................................................................... 967 Axle Air Breathing........................................................................................................................... 968 Special Tools................................................................................................................................ 969 List of Special Tools for Disassembly and Reassembly..................................................................................... 969 Axle Oils.................................................................................................................................... 976 Oil Grade ZF-Powerfluid.................................................................................................................. 976 Removal...................................................................................................................................... 977 Installation................................................................................................................................. 981 Completing Work.............................................................................................................................. 981 Disassembly And Reassembly................................................................................................................... 982 Disassembly Output and Brake............................................................................................................. 982 Disassembly Axle Housing................................................................................................................. 988 Disassembly Input........................................................................................................................ 989 Disassembly Differentials................................................................................................................ 992 Reassembly Differentials................................................................................................................. 999 Reassembly Input.........................................................................................................................1011 Reassembly Axle Housing..................................................................................................................1019 Reassembly Output and Brake..............................................................................................................1021 Driveshaft.......................................................................................................................................1035 Safety Instructions..........................................................................................................................1039 General......................................................................................................................................1040 Overview.................................................................................................................................1040 Specification............................................................................................................................1040 Removal (Front Drive Shaft)..................................................................................................................1042 Installation (Front DriveShaft)..............................................................................................................1044 Removal (Center Drive Shaft).................................................................................................................1045 Installation (Center DriveShaft).............................................................................................................1047 Removal (Rear Drive Shaft)...................................................................................................................1048 Installation (Rear DriveShaft)...............................................................................................................1049 Steering.............................................................................................................................................1051 Power Steering System............................................................................................................................1053 Safety Instructions..........................................................................................................................1057 General Description..........................................................................................................................1057 Overview.................................................................................................................................1058 Hydraulic Circuit........................................................................................................................1059 Theory of Operation......................................................................................................................1060 Steering Unit....................................................................................................................................1063 Safety Instructions..........................................................................................................................1067 General Description..........................................................................................................................1067 Specifications...........................................................................................................................1069 Overview.................................................................................................................................1070 Theory of Operation......................................................................................................................1071 Gerotor Operation........................................................................................................................1072 Relief Valve.............................................................................................................................1072 Steering Pump....................................................................................................................................1073 Safety Instructions..........................................................................................................................1077 General Description..........................................................................................................................1078 Specifications...........................................................................................................................1078 Overview.................................................................................................................................1079 Theory of Operation......................................................................................................................1082 Removal......................................................................................................................................1084 Installation.................................................................................................................................1089 Completing Work..............................................................................................................................1089 Disassembly..................................................................................................................................1090 Assembly.....................................................................................................................................1092 Flow Amplifier...................................................................................................................................1095 Safety Instructions..........................................................................................................................1099 General Description..........................................................................................................................1099 Specifications...........................................................................................................................1100 Parts List...............................................................................................................................1102 Theory of Operation......................................................................................................................1103 Removal......................................................................................................................................1105 Installation.................................................................................................................................1108 Completing Work..............................................................................................................................1108 Tools........................................................................................................................................1109 List of Required Tools...................................................................................................................1109 Disassembly..................................................................................................................................1110 Assembly.....................................................................................................................................1124 Cleaning and Inspection (Wear Limits and Tolerances).........................................................................................1138 Cleaning.................................................................................................................................1138 Inspection and Replacement...............................................................................................................1138 Lubrication..............................................................................................................................1138 Jerk Softener and Accumulator....................................................................................................................1139 Safety Instructions..........................................................................................................................1143 General Description..........................................................................................................................1143 Operation................................................................................................................................1143 Accumulator..................................................................................................................................1144 Specifications...........................................................................................................................1144 Dual Cross Relief Valve......................................................................................................................1144 Specifications...........................................................................................................................1144 Parts List...............................................................................................................................1144 Brake................................................................................................................................................1145 Service Brake....................................................................................................................................1147 Safety Instructions..........................................................................................................................1151 General Description..........................................................................................................................1152 Service Brake System.........................................................................................................................1153 Brake & Pilot Supply Valve.......................................................................................................................1155 Safety Instructions..........................................................................................................................1159 General Description..........................................................................................................................1159 Overview.................................................................................................................................1160 Parts List...............................................................................................................................1162 Removal......................................................................................................................................1163 Charging Block...................................................................................................................................1169 Safety Instructions..........................................................................................................................1173 General Description..........................................................................................................................1174 Parts List...............................................................................................................................1174 Parking Brake....................................................................................................................................1177 Safety Instructions..........................................................................................................................1181 General......................................................................................................................................1181 Specification............................................................................................................................1181 Overview.................................................................................................................................1182 Parts List...............................................................................................................................1183 Theory of Operation......................................................................................................................1184 Installing and Setting Instructions..........................................................................................................1186 Installing the Brake.....................................................................................................................1186 Clearance Adjusting......................................................................................................................1187 Adjusting Instructions...................................................................................................................1188 Emergency Release of the Parking Brake.......................................................................................................1189 Maintenance and Repair Work..................................................................................................................1190 Maintenance and Replacement of the Lining Pads...........................................................................................1190 Replacing the Seals......................................................................................................................1193 Brake Pedal Valve................................................................................................................................1195 Safety Instructions..........................................................................................................................1199 General Description..........................................................................................................................1199 Specification............................................................................................................................1199 Theory of Operation......................................................................................................................1201 Accumulator......................................................................................................................................1203 Safety Instructions..........................................................................................................................1207 General Description.......................................................................................................................... 0 Layout...................................................................................................................................1210 Specifications...........................................................................................................................1210 Brake Filter.....................................................................................................................................1211 Safety Instructions..........................................................................................................................1215 Specification............................................................................................................................1216 Overview.................................................................................................................................1216 Parts List...............................................................................................................................1216 Cooling System.......................................................................................................................................1217 Cooling System...................................................................................................................................1219 Safety Instructions..........................................................................................................................1223 General Description..........................................................................................................................1223 Function.................................................................................................................................1224 Hydraulic Circuit........................................................................................................................1225 Fan Motor Pressure and Fan Speed.........................................................................................................1226 Checking Maximum Fan Speed...........................................................................................................1227 Fan and Brake Pump...............................................................................................................................1229 Safety Instructions..........................................................................................................................1233 General......................................................................................................................................1233 Specification............................................................................................................................1233 Sectional View...........................................................................................................................1234 Overview.................................................................................................................................1235 Port and Hydraulic Circuit...........................................................................................................1235 Parts List...............................................................................................................................1236 Theory of Operation......................................................................................................................1238 Circuit..............................................................................................................................1238 Control Section......................................................................................................................1239 Circuit Diagram Related to Fan Drive.................................................................................................1239 Pump EPPR Valve......................................................................................................................1240 Removal......................................................................................................................................1242 Installation.................................................................................................................................1245 Completing Work..............................................................................................................................1245 Disassembly..................................................................................................................................1246 Assembly.....................................................................................................................................1250 Tightening Torques.......................................................................................................................1255 Sealing Driveshaft.......................................................................................................................1255 Sealing Control Valve....................................................................................................................1257 Fan Motor........................................................................................................................................1259 Safety Instructions..........................................................................................................................1263 Specifications...........................................................................................................................1264 Overview.................................................................................................................................1264 Port and Hydraulic Circuit...........................................................................................................1264 Fan Control Valve................................................................................................................................1265 Safety Instructions..........................................................................................................................1269 General......................................................................................................................................1269 Specifications...........................................................................................................................1269 Port and Hydraulic Circuit...........................................................................................................1270 Hydraulic System.....................................................................................................................................1271 Main Pump........................................................................................................................................1273 Safety Instructions..........................................................................................................................1277 General......................................................................................................................................1277 Specification............................................................................................................................1277 Overview.................................................................................................................................1278 Theory of Operation......................................................................................................................1280 Parts List...............................................................................................................................1282 Structure................................................................................................................................1285 Removal......................................................................................................................................1287 Installation.................................................................................................................................1292 Completing work..............................................................................................................................1292 Disassembly..................................................................................................................................1293 Assembly.....................................................................................................................................1296 Troubleshooting..............................................................................................................................1299 Maintenance Instructions.....................................................................................................................1300 Main Control Valve...............................................................................................................................1301 Safety Instructions..........................................................................................................................1305 General Description..........................................................................................................................1305 Specification............................................................................................................................1306 Overview.................................................................................................................................1307 Hydraulic Circuit........................................................................................................................1308 Parts List...............................................................................................................................1310 Theory of Operation......................................................................................................................1312 Section View.................................................................................................................................1320 Removal......................................................................................................................................1321 Installation.................................................................................................................................1326 Completing Work..............................................................................................................................1326 Disassembly/Reassembly.......................................................................................................................1327 Pilot System.....................................................................................................................................1337 Safety Instructions..........................................................................................................................1341 General Description..........................................................................................................................1341 Fingertip Joystick...........................................................................................................................1342 Specification............................................................................................................................1342 Port Name................................................................................................................................1342 Parts List - 2 Lever.....................................................................................................................1343 Parts List - 3 Lever.....................................................................................................................1344 FNR Joystick.................................................................................................................................1345 Specification............................................................................................................................1345 Port Name................................................................................................................................1345 Overview.................................................................................................................................1345 Parts List...............................................................................................................................1346 Hydraulic System.................................................................................................................................1349 Safety Instructions..........................................................................................................................1353 Hydraulic Component and Oil Flow.............................................................................................................1354 Hydraulic Components.....................................................................................................................1354 Fan Drive Operation..........................................................................................................................1356 Parking Brake Release Operation..............................................................................................................1357 Service Brake Operation......................................................................................................................1358 Steering Operation...........................................................................................................................1359 Boom Raise Operation and Load Sensing........................................................................................................1360 Boom Down Operation..........................................................................................................................1361 Boom Floating Operation......................................................................................................................1362 Bucket Crowd Operation.......................................................................................................................1363 Bucket Dump Operation........................................................................................................................1364 Combined Bucket Crowd and Boom Down Operation................................................................................................1365 Load Isolate System (LIS)....................................................................................................................1366 Hydraulic System Troubleshooting.................................................................................................................1367 Safety Instructions..........................................................................................................................1371 Hydraulic System.............................................................................................................................1372 Engine Started but Machine Does Not Operate..............................................................................................1372 Hydraulic Oil Is Cloudy..................................................................................................................1373 Hydraulic Oil or Engine Overheated.......................................................................................................1374 Parking Brakes Does Not Work.............................................................................................................1375 Service Brakes Does Not Work.............................................................................................................1376 Boom, Bucket Speed Is Slow...............................................................................................................1377 Does Not Work the Boom Floating..........................................................................................................1378 Steering Wheel Is Heavy to Turn..........................................................................................................1379 Does Not Operated LIS....................................................................................................................1380 Frame................................................................................................................................................1381 Articulation Center..............................................................................................................................1383 Safety Instructions..........................................................................................................................1387 General Description..........................................................................................................................1387 Maintenance Standard.....................................................................................................................1388 Cabin............................................................................................................................................1391 Safety Instructions..........................................................................................................................1395 Cabin Identification.........................................................................................................................1395 Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).........................................................1395 Dimensions of Cabin Glass....................................................................................................................1397 Removal and Installation of Cabin Glass......................................................................................................1402 Removal of Cabin Glass...................................................................................................................1402 Installation of Cabin Glass..............................................................................................................1404 Counterweight....................................................................................................................................1409 Safety Instructions..........................................................................................................................1413 General......................................................................................................................................1414 Overview.................................................................................................................................1414 Oil Tank.........................................................................................................................................1415 Safety Instructions..........................................................................................................................1419 General Description..........................................................................................................................1419 Specifications...........................................................................................................................1419 Parts List...............................................................................................................................1420 Air Breather.............................................................................................................................1422 Fuel Tank........................................................................................................................................1423 Safety Instructions..........................................................................................................................1427 General Description..........................................................................................................................1427 Specifications...........................................................................................................................1427 Parts List...............................................................................................................................1428 Cylinders........................................................................................................................................1431 Safety Instructions..........................................................................................................................1435 General......................................................................................................................................1435 General Description......................................................................................................................1435 Specification............................................................................................................................1435 Parts List...............................................................................................................................1436 Theory of Operation......................................................................................................................1442 Seal of Cylinder.........................................................................................................................1443 Special Tools and Materials.................................................................................................................. 0 Rod Bushing (DD-bushing) Pushing-in Jig..................................................................................................1451 Disassembly..................................................................................................................................1452 Reassembly...................................................................................................................................1457 Troubleshooting..............................................................................................................................1461 Electrical System....................................................................................................................................1463 Electrical System................................................................................................................................1465 Safety Instructions..........................................................................................................................1469 Overview.....................................................................................................................................1469 Electric Supply System.......................................................................................................................1470 Engine Starting Circuit......................................................................................................................1472 Operation During Start Process...........................................................................................................1472 Operation After Start Process............................................................................................................1474 Engine Stop System...........................................................................................................................1475 Engine Emergency Start System................................................................................................................1476 Charging System..............................................................................................................................1477 Power Mode Control...........................................................................................................................1478 Engine Control System........................................................................................................................1479 Accelerator Pedal........................................................................................................................1480 Electrical Steering Control..............................................................................................................1481 Electric Joystick........................................................................................................................1482 Electric MCV Control.....................................................................................................................1483 Electric Joystick (Boom).................................................................................................................1484 Electric Joystick (Bucket)...............................................................................................................1485 Auto Idle Control........................................................................................................................1486 Electric Detent System.......................................................................................................................1487 Electrical Circuit.......................................................................................................................1487 Boom Kick-out............................................................................................................................1488 Return to Dig............................................................................................................................1489 Cooling Fan Control System................................................................................................................... 0 Electrical Diagram.......................................................................................................................1491 Parts of Cooling Fan Control System......................................................................................................1492 Operation of Cooling Fan Control System..................................................................................................1494 Emergency Steering System (Option)...........................................................................................................1496 Block Diagram............................................................................................................................1496 Emergency Steering System Electrical Circuit.............................................................................................1500 Lighting System..............................................................................................................................1502 Light Circuit............................................................................................................................1502 Monitoring System............................................................................................................................ 0 Monitoring System Schematic..............................................................................................................1508 Operation.................................................................................................................................... 0 Multifunction Display....................................................................................................................1513 Indication of Warning Lights.............................................................................................................1516 Indication of Indicator Lights...........................................................................................................1518 Graphic Information Area Display............................................................................................................. 0 User Menu................................................................................................................................1521 Information of Machine Operation.........................................................................................................1545 Failure Code.................................................................................................................................1552 Failure Code at Machine..................................................................................................................1552 Failure Code at Engine Side..............................................................................................................1556 Failure Code at Transmission Side........................................................................................................1571 Failure Code at Electric Steering Side...................................................................................................1575 FMIs (Failure Mode Identifier)...........................................................................................................1577 Windshield Wiper.............................................................................................................................1578 Front Windshield Wiper...................................................................................................................1578 Rear Windshield Wiper....................................................................................................................1580 Air Conditioner..................................................................................................................................1581 Safety Instructions..........................................................................................................................1585 General Description..........................................................................................................................1586 Internal and External Filters............................................................................................................1587 Air-conditioning System Layout...........................................................................................................1588 Air Conditioner/Heater Unit..............................................................................................................1590 Ambient Air Temperature Sensor...........................................................................................................1595 Compressor...............................................................................................................................1603 Receiver Dryer...........................................................................................................................1603 Troubleshooting..............................................................................................................................1604 Refrigerant System Repairs...................................................................................................................1606 Refrigerant Safe Handling Procedures.....................................................................................................1606 Repair and Replacement Procedure.........................................................................................................1607 Refrigerant Recovery.....................................................................................................................1609 Vacuuming Refrigerant System.............................................................................................................1609 Leakage Check............................................................................................................................1611 Refrigerant Charging.....................................................................................................................1611 Inspecting System For Leakage............................................................................................................1613 Option...............................................................................................................................................1615 Emergency Steering...............................................................................................................................1617 Safety Instructions..........................................................................................................................1621 General......................................................................................................................................1621 General Description......................................................................................................................1621 Specifications...........................................................................................................................1621 Parts List...............................................................................................................................1623 Caution for Installation.................................................................................................................1623 Installation Procedure.......................................................................................................................1624 Emergency Steering.......................................................................................................................1624 Emergency Steering - Electric............................................................................................................1626 After Installation Precautions...........................................................................................................1627 Emergency Steering Function Test.........................................................................................................1627 Emergency Steering Automatic Test........................................................................................................1628 Load Isolation System............................................................................................................................1629 Safety Instructions..........................................................................................................................1633 General......................................................................................................................................1633 General Description......................................................................................................................1633 Overview.................................................................................................................................1634 Hydraulic Circuit........................................................................................................................1636 Accumulator Charging Method..............................................................................................................1636 LIS Valve....................................................................................................................................1638 Specification............................................................................................................................1638 Accumulator..................................................................................................................................1640 Specification............................................................................................................................1640 Parts List...............................................................................................................................1640 Auto Grease System...............................................................................................................................1641 Safety Instructions..........................................................................................................................1645 General Description..........................................................................................................................1645 Location.................................................................................................................................1648 Theory of Operation...................................................................................................................... 0 Feeder...............................................................................................................................1651 Error Sensing........................................................................................................................1652 Pump.........................................................................................................................................1653 Overview.................................................................................................................................1653 The Central Lubrication Pump.........................................................................................................1653 Note on the Rating Plate.............................................................................................................1654 Location.................................................................................................................................1654 Specification............................................................................................................................1655 Parts List...............................................................................................................................1656 Approved Lubricants......................................................................................................................1664 Operation................................................................................................................................1665 Pump.................................................................................................................................1665 Fill Level Monitoring................................................................................................................1665 Malfunctions on Pump Unit in Progressive System......................................................................................1665 Maintenance, Repair......................................................................................................................1667 Maintenance..........................................................................................................................1667 Feeder.......................................................................................................................................1669 Feeder (Front Frame).....................................................................................................................1669 General Description..................................................................................................................1669 Location & Parts List................................................................................................................1670 Dimension............................................................................................................................1671 Main Feeder Connector................................................................................................................1673 Feeder (Rear Frame)......................................................................................................................1673 General Description..................................................................................................................1673 Overview.............................................................................................................................1673 Location & Parts List................................................................................................................1674 Dimension............................................................................................................................1675 Feeder (Tilt lever)......................................................................................................................1676 General Description..................................................................................................................1676 Overview.............................................................................................................................1676 Location & Parts List................................................................................................................1677 Dimension............................................................................................................................1678 Replace Hose Using Service kit...........................................................................................................1679 Hoses for Self Assembly..............................................................................................................1679 Troubleshooting..............................................................................................................................1681 Grease Pump Fault........................................................................................................................1683 Grease System Faults.....................................................................................................................1683 Schematic............................................................................................................................................1685 Hydraulic Schematic / Electrical Schematic.......................................................................................................1687 Hydraulic Schematic..........................................................................................................................1689 Electrical Schematic.........................................................................................................................1691
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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S.M
